Thin-Walled Metal Container

ABSTRACT

The present application describes a thin-walled single-serve perishable food container configured to be economically manufactured from metal and useable by a consumer in the existing single-serve metal container, for example, a disposable single-serve metal yogurt cup. The thin-walled container has a top flange coupled to a bottom with a cylindrical wall and a conical sidewall that extends inwardly from the top flange, such that a diameter of the bottom is less than a diameter of the top flange. The thin-walled container may house other foods, such as ground or pulverized organic or synthetic powdered mixtures or dried food. The container may also have a cover or lid that hermetically seals the contents.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application is a continuation of International Application No. PCT/US2020/057512, filed Oct. 27, 2020, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention generally relates to the field of single-serve food containers, for example, a single-serve yogurt container. Conventional yogurt containers are stored in plastic containers. However, plastic is not an ideal material to contain and store yogurt given permeability and/or thermal properties of conventional plastics. The present invention relates specifically to an economical high-speed manufactured thin-walled metal container configured to permit dense packing for shipping to a filling facility. The metal containers may also store food items, including perishable food items such as yogurt.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to a thin-walled metal container. The container includes a circular top flange laying within a plane and extending between an outside edge and a circular inside edge centered on a longitudinal, central axis. The circular inside edge has a first diameter. An edge portion extends from the flange outwardly from the central axis and bent inwardly toward the central axis. The cross-sectional shape of the edge portion has a curved portion with a first radius. A cylindrical wall extends perpendicular to, and from, the inside edge of the top flange and being parallel to the central axis. The cylindrical wall terminates at a wall edge, the cylindrical wall and the wall edge having the first diameter. A bottom including a circular central wall parallel to the top flange is centered upon the central axis. The central wall includes a trough at its periphery. The trough includes a depth and a cross-sectional shape having a second radius. The trough terminates at a bottom edge having a second diameter being less than the first diameter. A conical sidewall extends from the wall edge to the bottom edge.

Another embodiment of the invention relates to a metal container with a top flange, an edge, a cylindrical wall, a bottom, a conical sidewall, and a cover. The top flange is centered on a central axis. The top flange extends along a plane between an outside edge and a circular inside edge. The top flange has a first diameter. The edge extends radially from the top flange and the central axis and is bent inwardly toward the central axis. A cross-sectional shape of the edge has a curved portion with a first radius. The cylindrical wall extends perpendicular to and from the inside edge of the top flange. The cylindrical wall extends parallel to the central axis and terminates at a wall edge with the first diameter. The bottom has a circular central wall parallel to the plane and centered on the central axis. The central wall includes a trough with a depth and cross-sectional shape that has a second radius at its periphery. The trough terminates at a bottom edge that has a second diameter that is less than the first diameter. The conical sidewall extends from the wall edge to the bottom edge. The cover is coupled to the circular inside edge of the top flange and forms a hermetic seal to seal contents stored within the metal container.

Another embodiment of the invention relates to a thin-walled metal container with a circular top flange, an edge portion, a cylindrical wall, a bottom, a conical sidewall, and a cover. The circular top flange lies on a plane and extends between an outside edge and a circular inside edge centered on a central axis. The circular inside edge has a first diameter. The edge portion extends from the top flange outwardly from the central axis and bends inwardly toward the central axis. The cross-sectional shape of the edge portion has a curved portion with a first radius. The cylindrical wall extends perpendicular to, and from, the inside edge of the top flange and is parallel to the central axis. The cylindrical wall terminates at a wall edge, having the first diameter. The bottom has a circular central wall parallel to the top flange and is centered on the central axis. The central wall has a trough at its periphery with a depth and a cross-sectional shape defining a second radius. The trough terminates at a bottom edge with a second diameter that is less than the first diameter. The conical sidewall extends from the wall edge to the bottom edge. The cover encircles the circular inside edge of the top flange and forms a hermetic seal that pressure seals contents stored within the metal container.

Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

FIG. 1 is a perspective view of a thin-walled metal food container;

FIG. 2 is a side view of the container;

FIG. 3 is a top view of the container;

FIG. 4 is a bottom view of the container;

FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 2 ;

FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 2 ;

FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 2 ; and

FIG. 8 is a dimensioned drawing of a side cross-sectional view of the container.

DETAILED DESCRIPTION

The figures illustrate a thin-walled metal container 10 to store food items, such as yogurt and/or other perishable or non-perishable foods. The purpose of container 10 is to contain a food item and/or perishable food such as yogurt. The thin-walled metal container 10 may also function as a cereal bowl, infant food mix, and/or a powdered or ground drink container such as coffee, tea, and/or hot chocolate grounds. For example, container 10 includes an edible food, such as a breakfast cereal, oats, or coffee is sealed within an interior of the metal container. A user can brake or puncture the seal to access the edible food and combine it with another food mixture within the container and/or outside the seal. For example, a user removes the seal to pour milk from outside the seal on the breakfast cereal inside container 10.

Metal container 10 is configured and formed from metal to permit the use of such containers as a substitute for plastic containers for perishable foods. Metal containers 10 offer advantages relating to gas permeability and perishable food interaction. The reduction in gas permeability and perishable food properties of metal containers 10 outweigh the development efforts and production costs to manufacture a satisfactory metal container.

As shown in the figures, container 10 includes a circular top flange 12 laying within a plane and extending between an outside edge 14 and a circular inside edge 16 centered on a longitudinal, central axis 18. Top flange 12 has a length L1 between 0.15 and 0.25 inches wide, specifically 0.196±0.01 inches. Top flange 12 has a diameter ϕ1 in the range of 3.5 and 4 inches, specifically 3.695±0.2 inches. Circular inside edge 16 has a diameter ϕ2 that is less than diameter ϕ1 and is in the range of 3 and 3.75 inches, specifically 3.303±0.1 inches.

As shown, an edge portion 20 extends from flange 12 outwardly from the central axis 18 and is bent inwardly toward the central axis 18. Edge portion 20 may extend from its periphery inwardly toward the central axis 18 a length L2 between 0.08 and 0.086 inches but preferably extends inward 0.083 inches. For example, an edge length L3 is the difference between the top flange length L1 minus the inward bend of length L2. In various embodiments, length L3 is between 0.10 and 0.15 inches, specifically 0.11±0.02 inches. A thickness T1 of the bent top flange 12 is between 0.05 and 0.1 inches, specifically 0.086±0.01 inches. The cross-sectional shape of edge portion 20 has a curved portion 22 with a radius R1, which is between 0.03 and 0.035 inches, specifically 0.0315±0.001 inches.

A cylindrical wall 24 extends perpendicular to, and from, inside edge 16 of top flange 12. Cylindrical wall 24 is centered on and parallel to the central axis 18. Cylindrical wall 24 terminates at a wall edge 26 and has a diameter ϕ2 substantially the same as circular inside edge 16. Height H2 of the cylindrical wall may be between 0.3 and 0.4 inches, specifically 0.35±0.02 inches.

Bottom 25 of container 10 includes a circular central wall 28 parallel to top flange 12 and centered on and perpendicular to the central axis 18. Central wall 28 includes a trough 30 at its periphery. Trough 30 has a depth D1, which may be between 0.06 and 0.07 inches, specifically 0.068±0.001 inches. Trough 30 has a cross-sectional shape, which may have a radius R2 between 0.020 and 0.03 inches, specifically 0.024±0.01 inches. Trough 30 terminates at a bottom edge 32 having a diameter ϕ3 less than diameter ϕ2 of circular inside edge 16 and less than diameter ϕ1 of top flange 12. Specifically, diameter ϕ3 of bottom edge 32 is defined by an angle α between a conical sidewall 34 and the central axis 18, and a total height H1 of container 10 is between 1.5 and 3 inches, specifically between 2 and 2.5 inches, and more specifically is 2.3±0.1 inches.

In various embodiments, sidewall 34 has a vertical component or height H3 along the central axis 18 is between 1.25 and 2.5 inches, specifically between 1.85 and 1.95 inches and an angle α from the central axis 18 to sidewall 34 between 5 and 15 degrees, specifically between 7.5 and 12.5 degrees, and more specifically 10 degrees±0.5 degrees. Height H3 and/or angle α facilitate stacking and unstacking empty containers 10. Sidewall 34 angle α also facilitates the insertion and removal of containers 10 from a yogurt maker. Conical sidewall 34 extends from wall edge 26 to bottom edge 32. In some embodiments, container 10 also includes a transition wall 36, which extends between cylindrical wall 24 and sidewall 34.

Container 10 is made from a metal such as aluminum or a ferrous metal such as steel. The metal is impervious to oxygen, which protects perishable foods such as yogurt, or non-perishable foods such as grounds, tea leaves, cocoa and/or liquid yogurt, tea, cocoa, cereal, oats and/or other food items housed within container 10. An inside surface 33 and/or an outside surface 35 of container 10 may be coated with an appropriate polymer material. The polymer material improves the protection of the food product and/or manufacturability of container 10. After container 10 is filled with an associated yogurt material, a foil or plastic membrane is sealed (preferably heat-sealed with a temperature activated adhesive) to top flange 12.

Thickness T2 of bottom 25 (e.g., from inner surface 33 to outer surface 35 of central wall 28) is in a range that allows the manufacture of bottom 25 by a drawing and/or stamping process.

For an aluminum container 10, thickness T2 of bottom 25 and/or thickness T3 of sidewall 34 is in the range of 0.007-0.012 inches, specifically between 0.010±0.001 inches. For a steel container, thickness T2 of bottom 25 and/or thickness T3 of sidewall 34 is in the range of 0.004-0.006 inches, specifically between 0.005±0.0005 inches. Additionally, depending upon the metal used on the interior and/or exterior surfaces 33 and 35, container 10 may be coated with a polymer or plastic coating. For example, where container 10 is a ferrous metal such as steel, the coating may be Sherwin Williams 9840901VR or Akzo Nobel 657E704.

FIGS. 1-4 show container 10 with an optional cover 38 to hermetically seal contents 42 of container 10. Contents 42 may be liquid, solid, powder, edible, organic, inorganic, and/or synthetic. Cover 38 has a diameter ϕ4 that is between outer edge 14 diameter ϕ1 and inner edge 16 diameter ϕ2. Specifically, diameter ϕ4 is equal to or less than diameter ϕ1 and is equal to or greater than diameter ϕ2. For example, cover 38 couples to circular inside edge 16 of top flange 12. In some embodiments, cover 38 forms a pressured or vacuum seal and is impervious to ambient air, water, or other fluids. For example, a positive pressure differential or a negative pressure differential (vacuum) can be applied to the contents 42 of container 10 to preserve the organic, edible, and/or consumable powder contents 42. Specifically, cover 38 couples to container 10 to form a hermetic seal that isolates the contents 42 of container 10 from microbes, viruses, debris, water, and/or air in the surrounding environment.

FIG. 5 further illustrates cover 38 over a container 10 with food contents 42. Cover 38 couples to inside edge 16 and extends into an interior formed within inner surfaces 33 of sidewall 34 and bottom 25. Cover 38 couples to top flange 12 on or between inside edge 16 and/or outside edge 14. For example, cover 38 couples to top flange 12 and extends from outside edge 14 to inside edge 16 and within the interior of container 10 (between cylindrical wall 24 and sidewall 34) to house or store food contents 42 such as yogurt and/or other food or ground particulates. In various embodiments, an interior or inner surface 33 and/or exterior outer surface 35 of cover 38, sidewall 34, and/or bottom 25 are coated with PET laminate, BPA Non-Intent Liquid Coating, and/or other preservatives that preserve the organic, edible, and/or consumable nature of the food contents 42 housed within the container 10 product.

FIG. 6 is a cross-sectional view of the top half of container 10 taken along line 6-6 of FIG. 2 . Similarly, FIG. 7 is a cross-section view of the bottom half of container 10 taken along line 7-7 of FIG. 2 . These views show interior surface 33 and exterior surface 35 of sidewall 34 and inner surface 33 of bottom 25.

FIG. 8 shows dimensions for one embodiment of container 10. The figures are illustrated such that the dimensions and angles shown therein are drawn proportional to each other. As described above, flange 12 has a diameter ϕ1 in the range of 3.5 and 4 inches, circular inside edge 16 has a diameter ϕ2 that is less than diameter ϕ1, and bottom edge 32 has diameter ϕ3 that is less than diameter ϕ2 and ϕ1. Cover 38 diameter ϕ4 is equal to or less than diameter ϕ1 and is equal to or greater than diameter ϕ2.

A total height H1 of container 10 is between 1.5 and 3 inches. A height H2 of cylindrical wall 24 is between 0.3 and 0.4 inches, such that the height H3 of sidewall 34 along central axis 18 is between 1.25 and 2.5 inches. A length L1 of top flange 12 includes the inward bend length L2 and edge length L3. In other words, L1 represents the width or length of top flange 12, including the bend length L2 and edge length L3 of container 10. Similarly, the bend radius R1 creates a thickness T1 for flange 12.

Thickness T2 of bottom 25 and thickness T3 of sidewall 34 are also selected to improve manufacturability and fabrication of container 10, e.g., through a stamping process. Depth D1 of trough 30 on bottom edge 32 increases the stackability and/or the stability of container 10. For example, depth D1 improves the stability of metal container 10 on a level surface. Bend radii R1 and R2 of flange 12 and trough 30 are selected to enhance stability, manufacturability, and/or functionality.

It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions, and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

In various exemplary embodiments, the relative dimensions, including angles, lengths, and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles, and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles, and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.

According to exemplary embodiments, the containers, and specifically the container sidewalls and bottom, discussed herein are formed from metal and specifically may be formed from stainless steel, tin-coated steel, aluminum, etc. In some embodiments, the containers discussed herein are formed from aluminum, and the can ends, or membranes are formed from tin-coated steel. In some embodiments, the sidewall of the container is formed from a metal material, and other metals or materials (e.g., polymers, high-temperature plastic, thermoplastics, cardboard, ceramic, etc.) are used to form the end walls of the container.

Containers discussed herein may include containers of any style, shape, size, etc. For example, the containers discussed herein may be shaped such that cross-sections taken perpendicular to the longitudinal axis of the container are generally circular. However, in other embodiments, the sidewall of the containers discussed herein may be shaped in a variety of ways (e.g., having other non-polygonal cross-sections, as a rectangular prism, a polygonal prism, any number of irregular shapes, etc.) as may be desirable for different applications or aesthetic reasons. In various embodiments, the sidewall of container ϕ0 may include one or more axially extending sidewall sections that are curved radially inwardly or outwardly such that the diameter of the can is different at different places along the axial length of the can, and such curved sections may be smooth continuous curved sections. In one embodiment, container 10 may be hourglass-shaped. Container 10 may be of various sizes as desired for a particular application.

Further, a container may include a container end (e.g., a closure, lid, cap, cover, top, end, can end, sanitary end, “pop-top,” “pull-top,” convenience end, convenience lid, pull-off end, easy open end, “EZO” end, etc.). The container end may be any element that allows the container to be sealed such that the container is capable of maintaining a hermetic seal. In an exemplary embodiment, the upper can end may be an “EZO” convenience end, sold under the trademark “Quick Top” by Silgan Containers Corp.

In various embodiments, the upper can end may be a closure or lid attached to the body sidewall mechanically (e.g., snap on/off closures, twist on/off closures, tamper-proof closures, snap-on/twist-off closures, etc.). In another embodiment, the upper can end may be coupled to the container body via the pressure differential. The container end may be made of metals, such as steel or aluminum, metal foil, plastics, composites, or combinations of these materials. In various embodiments, the can ends, double seams, and sidewalls of the container are adapted to maintain a hermetic seal after the container is filled and sealed.

The containers discussed herein may be used to hold perishable materials (e.g., food, drink, pet food, milk-based products, etc.). It should be understood that the phrase “food” used to describe various embodiments of this disclosure may refer to dry food, moist food, powder, liquid, or any other drinkable or edible material, regardless of nutritional value. In other embodiments, the containers discussed herein may be used to hold non-perishable materials or non-food materials. In various embodiments, the containers discussed herein may contain a product that is packed in a liquid that is drained from the product prior to use. For example, the containers discussed herein may contain vegetables, pasta, or meats packed in a liquid such as water, brine, or oil.

According to various exemplary embodiments, the inner surfaces of the upper and lower can ends and the sidewall may include a liner (e.g., an insert, coating, lining, a protective coating, sealant, etc.). The protective coating acts to protect the material of the container from degradation that may be caused by the contents of the container. In an exemplary embodiment, the protective coating may be a coating that may be applied via spraying or any other suitable method. Different coatings may be provided for different food applications. For example, the liner or coating may be selected to protect the material of the container from acidic contents, such as carbonated beverages, tomatoes, tomato pastes/sauces, etc. The coating material may be a vinyl, polyester, epoxy, EVOH, and/or other suitable lining material or spray. The interior surfaces of the container ends may also be coated with a protective coating, as described above. 

What is claimed is:
 1. A thin-walled metal container comprising: a circular top flange laying within a plane and extending between an outside edge and a circular inside edge centered on a longitudinal, central axis, the circular inside edge having a first diameter; an edge portion extending from the top flange outwardly from the central axis and bent inwardly toward the central axis, wherein a cross-sectional shape of the edge portion has a curved portion having a first radius; a cylindrical wall extending perpendicular to, and from, the inside edge of the top flange and being parallel to the central axis, the cylindrical wall terminating at a wall edge having the first diameter; a bottom including a circular central wall parallel to the top flange and centered upon the central axis and terminating at a bottom edge that has a second diameter that is less than the first diameter; and a conical sidewall extending from the wall edge to the bottom edge.
 2. The container of claim 1, wherein the first diameter is between 3 and 3.75 inches.
 3. The container of claim 1, wherein a width of the top flange is between 0.15 and 0.25 inches.
 4. The container of claim 1, wherein the first radius is between 0.03 and 0.035 inches.
 5. The container of claim 1, wherein the cylindrical wall extends between 0.3 and 0.4 inches between the inside edge of the top flange and the wall edge.
 6. The container of claim 1, wherein the edge portion is bent inwardly between 0.08 and 0.086 inches from the top flange toward the central axis.
 7. The container of claim 1, wherein the radius is between 0.022 and 0.026 inches.
 8. The container of claim 1, wherein the conical sidewall extends at an angle from the bottom between 5° and 15° degrees from the central axis.
 9. The container of claim 1, wherein the container is fabricated from aluminum.
 10. The container of claim 1, wherein the container is fabricated from ferrous metal.
 11. The container of claim 1, wherein an inside surface of the container is coated with PET Laminate, BPA Non-Intent Liquid Coating.
 12. The container of claim 1, wherein an outside surface of the container is coated with PET Laminate, BPA Non-Intent Liquid Coating.
 13. A metal container, comprising: a top flange extending along a plane between an outside edge and a circular inside edge with a first diameter, the top flange centered on a central axis; a cylindrical wall extending perpendicular to, and from, the inside edge of the top flange and being parallel to the central axis, the cylindrical wall terminating at a wall edge having the first diameter; a bottom including a circular central wall parallel to the plane, the bottom is centered on the central axis, the central wall including a trough at its periphery, the bottom terminates at a bottom edge that has a second diameter that is less than the first diameter; a conical sidewall extending from the wall edge to the bottom edge; and a cover coupled to the circular inside edge of the top flange, the cover forming a hermetic seal that seals contents stored within the metal container.
 14. The container of claim 13, wherein the cover extends from the inside edge to the outside edge of the top flange.
 15. The container of claim 13, wherein the cover of the container is coated with PET Laminate, BPA Non-Intent Liquid Coating, and wherein the cover comprises a metallic material.
 16. The container of claim 13, further comprising an edible food sealed within an interior of the metal container, and wherein the food is combined with a food mixture outside the seal.
 17. A thin-walled metal container, comprising: a circular top flange laying within a plane and extending between an outside edge and a circular inside edge centered on a longitudinal, central axis, the circular inside edge having a first diameter; an edge portion extending from the top flange outwardly from the central axis and bent inwardly toward the central axis, wherein a cross-sectional shape of the edge portion has a curved portion having a first radius; a cylindrical wall extending perpendicular to, and from, the inside edge of the top flange and being parallel to the central axis, the cylindrical wall terminating at a wall edge having the first diameter; a bottom including a circular central wall parallel to the top flange and centered upon the central axis, the central wall including a trough at its periphery, the trough including a depth and a cross-sectional shape having a second radius with the trough terminating at a bottom edge having a second diameter being less than the first diameter; a conical sidewall extending from the wall edge to the bottom edge; and a cover encircling the circular inside edge of the top flange, the cover forming a hermetic seal that pressure seals contents stored within the metal container.
 18. The container of claim 17, wherein the contents stored within the metal container are a liquid material.
 19. The container of claim 17, wherein the contents stored within the metal container are an edible perishable material sealed under a pressure differential.
 20. The container of claim 19, wherein the edible perishable material contents stored within the metal container are an instant yogurt in a single-serve metal yogurt container, and the pressure seal is a vacuum seal. 